Foam core panel for prefabricated buildings

ABSTRACT

The present invention relates to a building panel for forming walls, roofs and floors in a building constructed with a frame including an expanded foam plastic core rectangular in shape, circular voids extending through the thickness of said core, each of the plurality of circular voids spaced apart to receive tension members, a coating applied to at least one face providing added rigidity and a frame comprising elongated members having channels sized to fit on the end faces of the panels for joining a pair of said building panels together.

FIELD OF THE INVENTION

This invention relates to a prefabricated building assembly for low-cost construction of walls, roofs, and floors that includes the use of a plurality of prefabricated building modules made of panels having a foam plastic core of the desired thickness, with the side edges of the building panel having prefabricated semicircular channels that engage tubular connectors for joining the panels together to form walls, roofs, and floors. Each panel also includes a polymer coating, corrugated plastic or wood sheeting on its outsides to provide a finish, structural strength, and rigidity. Each panel also includes a plurality of circular bores or voids that extend all the way through the thickness of the panel across the width of each panel from side to side, each of the passages being parallel and spaced at a predetermined and equal distance apart to accommodate partially threaded steel rods or cables which fasten the modules together to provide rigidity for the structure.

The modules may be used to construct walls of various sizes provided that the diameter of the tubular members or pipes vary accordingly. Tubular flange type connectors are inserted at the bottom of each pipe to secure the wall units to the floor by fastening means such as screws. The pipes or channels may be made of plastic or metal.

Plywood or cement floors or foundations are also possible with system. The building system may be used vertically for traditional or arch-type buildings and for dome-type structures. The exterior of the modules is preferably covered with a waterproof fabric such vinyl.

BACKGROUND OF THE INVENTION

U.S. Pat. No. 4,194,919 to Hattori, et al., describes a method for increasing flexural strength of cement compositions. The flexural strength of hydraulic cement compositions are increased by water-soluble epoxy resins.

U.S. Pat. No. 5,921,046 to Hammond, et al., provides a plastic foam core for epoxy cement concrete. There is no description or discussion to provide a foam core with a coating of epoxy resin and plastic pipe as described in Applicant's invention herein.

None of the references cited herein disclose Applicant's building block having a foam core with an integral vertical plastic pipes nor provide a low-cost lightweight construction block that includes preformed voids for horizontal steel rods and a low-cost permanent coating that prevents lateral buckling.

SUMMARY OF THE INVENTION

A prefabricated building assembly for constructing walls, roofs, and floors, comprising a prefabricated building panel made up of substantially a foam plastic core. Each of the building panels has horizontal spaced circular voids to receive threaded steel rods or cables.

The side face of the building panel includes a half-round or semicircular groove or channel faces. The purpose of these semicircular channels is to provide connection between adjacent panels when joined together, such that a cylindrical circular connector is disposed therein for alignment and connection of adjacent panels.

The building panel includes an epoxy or acrylic resin coating, corrugated plastic board or plywood on its side walls to provide strength and a finished surface on the plastic foam core of the building panel. The connector system, which includes a plurality of cylindrical, elongated members, which are also made of plastic and may be filled with foam. The basic foam panel is also coated with the epoxy or acrylic resin. The coating is also used as adhesive along the connectors and wall interface.

The building panel also includes a plurality of small passageways, both horizontally and vertically disposed, for electrical wiring, the passageways being approximately ¾ in. in diameter.

The building assembly may be used to construct walls, roofs, and floors. The building assembly system described herein can also be used to form roof connections and a building roof with supporting trusses.

One of the purposes of the building assembly in the present invention is the use of styrene or urethane foam blocks for the construction, that it can be prefabricated in a factory environment and then shipped to the building site, so that less manual labor or finishing is required. The building assembly in accordance with the present invention has impact and compressive load strength. When using the present building assembly, the time of construction is greatly reduced. The building panels and assembly connectors are prefabricated in a factory and come in a finished condition.

After the footer and slab have been poured, a building panel in accordance with the present invention will be placed on top of tubular flange connectors that are secured to the slab by screws. A roof type second building panel will be mounted on top of the first building panel and will include cylindrical connectors. Again, the epoxy or acrylic resin coating can be used for adhering the cylindrical connectors to the recessed walls of each of the building blocks, apart in the building panels, with the tubes progressing vertically up to the top of the wall. The same construction technique can be used on roofs, as described in greater detail below.

The present invention seeks to provide a building panel for forming walls, roofs and floors in a building constructed with a tubular frame including an expanded foam, plastic core substantially rectangular in shape, first and second faces defined by the ends of said core, the end faces each having a concave, semicircular recessed channel, said core also including a plurality of circular voids extending through the thickness of said core between said first and second face, each of said plurality of said circular voids being essentially parallel and each of said circular voids being spaced apart to receive tension members, a plastic resin forming a coating, integrally applied to at least said first face, said coating being approximately one quarter inch thick for added rigidity; and the tubular frame comprising cylindrical, elongated members, sized in radius to fit snugly within said semicircular recessed channels in the core faces, said connector being formed of a plastic pipe for joining a pair of said building panels together.

The present invention also seeks to provide a panel, wherein the building panel foam expanded plastic core is made of styrene or acrylic the building panel plastic foam core is made of urethane and wherein the frame is constructed of channel members which engage the sides of the plastic foam panel.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of wall and roof panels in accordance with this invention

FIG. 2 is a perspective view of side by side panels

FIG. 3 is a perspective view of an assembled building structure

FIG. 4 is a perspective view of a dome shaped building structure, and

FIG. 5 is a perspective view of the pipe arrangement of the structure of FIG. 3.

DESCRIPTION OF THE PREFERRED EMBODIMENT

The building assembly in accordance with the present invention uses prefabricated modules. These modules or panels 10 comprise rigid foam plastic that has wood sheeting 11 provided with adhesive on both interior and exterior sides of panels to ensure its rigidity as shown in FIG. 1-5. Both vertical sides of panels have a semicircular concave recessed vertical channel 14, to receive a plastic pipe 16 of the same diameter provided with adhesive as shown in FIG. 1-2. Each building panel is provided with horizontal holes or voids ( 5/16 in.) 20, in order to insert partially threaded, 24 in. long, reinforcing steel rods 12 spaced every 2 ft., as shown in FIG. 1-2 and 4-5. A washer 26 and bolt connector 28 is placed on reinforcing steel rods 12 outside of vertical plastic pipe 16 as shown in FIGS. 2 and 4. The steel connector 28 is used to join the horizontal reinforcing steel rods 12 after each panel is in place to secure the panels 10 together in order to form one unit as shown in FIGS. 2, 4 and 5. Plastic or metal angled connectors 30, 30 a with set screws 38 are used, to join side wall panels to roof panels as shown in FIG. 3-4. In addition, the wall panels have a pre-determined angle at the top 15, where as the roof panels have a pre-determined angle at the top 15 a and bottom 15 b, in order for both panels (wall and roof or both roof panels) to join perfectly to create a 45 degree angle, as shown in FIG. 1. A metal anchor connector 30 b is used, with set screw 38, at bottom of each pipe 16 on either side of panels to secure them to the foundation with 3 or 4 lag screws 36 at predrilled holes on steel plate of connector, whether it is wood or concrete as shown in FIG. 2-5. The building unit is covered with a waterproof, fire retardant and U.V. protected vinyl membrane 22 which has a horizontal loop 32 placed at the bottom of each side, to insert a horizontal plastic or metal pipe 34, as shown in FIG. 4-5. It is fastened with lag screws 36 spaced every foot of the foundation or floor, whether it is concrete or wood as shown in FIG. 2-5. Specifications above, also apply to arch-type dome or semi-circular structures as shown in FIG. 5. It is very important that all dimensions of materials are subject to change depending on the size of building required. 

What we claim is:
 1. A building panel for forming walls, roofs and floors in a building constructed with a frame comprising: an expanded foam, plastic core substantially rectangular in shape, first and second faces defined by the ends of said core, said core also including a plurality of circular voids extending through the thickness of said core between said first and second face, each of said plurality of said circular voids being essentially parallel and each of said circular voids being spaced apart to receive tension members, a coating, applied to at least said first face, said coating providing added rigidity; and said frame comprising elongated members having channels and being sized to fit on the end faces of the panels for joining a pair of said building panels together.
 2. A panel for walls, roofs and floors as in claim 1, wherein said coating on said building panel is plywood.
 3. A panel as in claim 1, wherein said building panel foam expanded plastic core is made of styrene.
 4. A panel as in claim 1, wherein said building panel plastic foam core is made of urethane.
 5. A panel as in claim 1, wherein said frame is plastic pipe of a diameter to fit in recessed channels in the end faces of the panels.
 6. A panel as claimed in claim 1 wherein said coating on said building panel is corrugated plastic board. 